6000-Series Super Tugger
®
Cable Pullers
Greenlee Tools, Inc.
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
27
Maintenance
(cont’d)
Replacing the Frame
Electric shock hazard:
Disconnect the cable puller from the
power supply before servicing.
Failure to observe this warning could
result in severe injury or death.
Replace the frame if appears damaged. During disas-
sembly, inspect each part. Replace any worn, damaged,
or missing parts with Greenlee replacement parts.
Replace the needle bearings (74 and 75) regardless of
their appearance.
1. Remove the left outer guard (4). Remove the lubri-
cating screw (5), washers (6-9), and capstan unit
(10-19).
2. Remove the #60 chain (20). Remove the sprocket
(22), washers (23), and guard (25).
3. Remove the right outer guard (69). Remove the #40
chain.
4. Remove the retaining ring (67), #60 sprocket (31),
and all items located on the sprocket (32-37 and
68-75). Discard the needle bearings (74 and 75).
5. Remove cap screw (45) and all items of the eccen-
tric assembly (46-49).
6. Remove the cap screw (26) and all items of the idler
assembly (27-30).
7. Remove the switch housing (54) and components.
8. Remove the motor, handle, sheave, ratchet pawl
and feet.
9. Assemble items to the new frame in reverse order.
Notes: Replace any components that show signs of
wear or damage.
When replacing the items of the sprocket (31)
assembly, install new needle bearings (74 and 75).
Install the clip of each connecting link so that the
closed end of the clip faces the direction of chain
travel, as shown in the Exploded View.
Troubleshooting the Electrical Circuit
Electric shock hazard:
Disconnect the cable puller from the
power supply before servicing.
Failure to observe this warning could
result in severe injury or death.
See the wiring diagram. Use a continuity checker to
check the electrical circuit. Lack of continuity in the fol-
lowing procedure indicates that a repair is necessary.
1. Unplug the puller.
2. Set the switches to ON.
3. Place the probes of the continuity checker across
the following terminals of the cable puller and force
gauge. All of these pairs of terminals should have
continuity.
To check the switches:
A and B
Q and R
S and T (220 volt models only)
X and Y (220 volt models only)
To check the connectors:
G and A
H and D
I and J
K and S
L and O
M and N
U and N
V and R
W and K (120 volt models only)
W and T (220 volt models only)
To check the bridge rectifier:
C and D
E and F
To check the ammeter:
O and P
To check the motor:
C and E
If the motor fails this check, inspect the motor compo-
nents (brushes, armature, and wires). Replace any parts
that are worn or damaged. Replace both brushes if
either brush measures less than 3/8" long.
